Academic Credentials
  • Ph.D., Materials Science, University of Rochester, 2007
  • M.S., Materials Science and Engineering, Rochester Institute of Technology, 2001
  • M.E., Mechanical Engineering, Rensselaer Polytechnic Institute, 1997
  • B.S., Mechanical Engineering, Rensselaer Polytechnic Institute, 1993
Licenses & Certifications
  • Professional Engineer Mechanical, Arizona, #80192
  • Professional Engineer, Maryland, #41592
  • Professional Engineer, New York, #79001
  • Six Sigma Black Belt Certification (CSSBB)
Professional Honors
  • Tau Beta Pi
  • Pi Tau Sigma
  • Society of Plastics Engineers ANTEC Best Paper Award
Professional Affiliations
  • Society of Plastics Engineers (Senior Member)
  • SPE Failure Analysis & Prevention Group - Board Member and Treasurer
  • ASTM D20 Plastics Committee Member
  • Plastic Pipe Institute (PPI) Member

Dr. MacLean is the Practice Director and a Principal of Exponent's Polymer Science and Materials Chemistry Practice. His research is focused on the chemical and physical behavior of polymeric materials in end-use applications.

Dr. MacLean's specialties include part design and analysis, failure analysis, material specification, formulation-structure-property relationships, testing, as well as patent and trade secret analysis. He has studied various polymer failure mechanisms including stress overload, creep rupture, fatigue, environmental stress cracking, delamination and weathering. Throughout his career he has evaluated the suitability of materials for the automotive, sporting goods, medical and drug delivery device, consumer products, oil and gas, electrical, pipe, and construction industries. Dr. MacLean assists clients in assessing risk in all stages of product life including product development, reliability testing and long-term field performance.

Dr. MacLean is well versed in product recall investigations led by the Consumer Product Safety Commission (CPSC), the National Highway Traffic Safety Administration (NHTSA) and the National Transportation Safety Board (NTSB). He is familiar with the processes of each federal agency regarding the investigation, analysis, and remedies of underperforming products and components. Dr. MacLean is also familiar with testing and material standards published by ASTM International, International Standards Organization (ISO), Underwriters Laboratories (UL), International Electrotechnical Commission (IEC) and the Society of Automotive Engineers (SAE).

Over the past 25 years, Dr. MacLean has worked on a variety finished goods produced from polymer and composite manufacturing processes including injection molding, compression molding, blow molding, blown film, rotational molding, extrusion, fiber spinning, thermoforming, calendering, and laminating. In addition, he has investigated material systems which include secondary operations such as metallic plating, coatings, adhesives, paints and welding.

Prior to joining Exponent, Dr. MacLean spent 16 years in the polymer manufacturing industry at General Electric (GE) Plastics and SABIC where he held several technical and leadership positions of increasing responsibility. His responsibilities included material development, processing and selection, testing for high-demand applications, product safety assessments, failure analysis, and intellectual property analysis.